Method of making scraggy rugs



April 5, 1949. 1. FALLEK 2,466,016

METHOD OF MAKING SCRAGGY RUGS Filed 0ct.-l, 1946 2 Sheets-Sheet 1 .2: 1 1 d 2! I; I 7 g INVENTOR.

5 1 IRVING FALLEK BY 59M A'r ORNEYS p 1949. 1. FALLEK METHOD OF MAKING SCRAGGY HUGS Filed 001;. 1,' 1946 2 Sheets-Sheet 2 INVENTOR.

I r-z v Me FAL. EK

A T TO RN EYS Patented Apr. 5, 1949 UNITED STATES PATENT OFFICE METHOD OF MAKING SCRAGGY RUGS Irving Fallek, San Francisco, Calif.

Application October 1, 1946, Serial No. 700,399

5 Claims.

An object of my invention is to provide a method and means for making a scraggy rug. The usual way of making such a rug is to form the tufts independently and then secure them individually to the fabric or foundation piece. With my invention the tufts may be applied to stamped foundations simply, speedily and uniformly and with a minimum of effort and waste.

A further object of my invention is to provide a spacer guide to be used in forming tufts from a bundle of strands of yarn that are grouped together for forming a tuft of the desired size. The spacer guide determines the length of the strands of yarn for forming each tuft and also indicates the place for tieing each tuft on the marked portion of the foundation piece. In this way the tufts are successively made and are positioned and secured to the foundation piece in the course of being made.

A further object of my invention is to provide a device of the type described that makes use of a needle of novel construction for securing the bundle of yarn to the foundation piece at equal spaces, after which the sections lying between the spaced securing means may be cut at their centers by means of a scissors or cutting tool. The cut sections form the tufts.

In a modified form of the invention the length of the strands forming the tufts is increased so that a scraggy rug formed of longer tufts results.

Other objects and advantages will appear in the following specification, and the novel features of the device will be particularly pointed out in the appended claims.

My invention is illustrated in the accompanying drawing forming a part of this application, in which:

Figure 1 is a perspective view of a foundation piece and illustrates how the bundle of yarn strands are secured to the piece at equal spacings. preparatory to cutting the strands midway between adjacent fastenings for forming the strands into tufts;

Figure 2 is a schematic showing of how the strands are secured to the foundation piece;

Figure 3 illustrates the first step in the method of securing the strands to the foundation piece;

Figure 4 illustrates the second step in the method;

Figure 5 is a transverse section showing one completed tuft and how the bundle of yarn strands are secured at equal spaces along the foundation piece preparatory to forming additional tufts;

Figure 6 is a top plan View of the spacer guide;

Figure 7 is a side elevation of Figure 6;

Figure 8 is a front elevation of Figure 7;

Figure 9 is a top plan view of the needle shank;

Figure 10 is a side elevation of Figure 9; and

Figure 11 is a bottom plan view of the needle shank.

While I have shown only the preferred form of my invention, it should be understood that various changes or modifications may be made Within the scope of the appended claims without departing from the spirit and scope of the invention.

In carrying out my invention, I make use 01' a foundation piece indicated generally at A in Figure 1. This piece is suitably stamped, printed or drawn with a design and stretched on a frame B with the design on top. The frame members I and 2 grip the cloth therebetween. The frame may be of any size and shape desired and the foundation piece may be made of any material desired. On the foundation piece I indicate a guide line 3 that shows where to secure the tufts to the foundation piece. In actual practice the foundation piece will have a plurality of guide lines or a single line of a definite shape may be used so that when tufts are secured at spaced distances along the single or multiple lines, the entire foundation piece will be covered with the tufts. The strands of yarn may be of different colors so pleasing designs may be worked out with the tufts.

I make use of a spacer guide indicated generally at C in Figures 6 to 8, inclusive, and I will describe the construction of this guide before setting forth the method of making the rug. The guide comprises a body member 4 which is preferably of metal and the body has prongs 5 and 6 that are struck down from it as illustrated. The distance between the prongs will determine the distance between the tufts. In the form shown the distance is about one inch. The end of the body projecting beyond the prong 5 is made in the form of an inverted U as indicated at I; in Figure 7, and an eye 8 is formed at the top of the U portion or toe, the axis of the eye paralleling the longitudinal axis of the body.

The bundle of yarn strands indicated generally at D in Figure 5 is fed through the eye 8 and the eye holds the strands in a cylindrical form. The

end of the bundle extends beyond the eye in the direction of the toe about one inch. The other end of the bundle, if too long, may be loosely knotted so it can be more easily managed.

Before describing the steps in the method of forming the rug, it is best to describe the construction of the needle and this is shown in detail in Figures 3, 4 and 9 to 11, inclusive. The needle E has a handle 9 and a shank I0 projects from the handle so that the shank axis coincides with the handle axis. The end of the needle shank I 0 is curved at H and is provided with an eyelet l2 for receiving the tieing yard strand that secures the tufts to the foundation piece.

The front or upper side of the needle shank has a groove I3 communicating with the eyelet l2 and extending toward the handle E a short distance. The back of the needle has a much longer groove N that extends from the eyelet 12 almost to the handle and the groove l4 has a portion Ma extending from the eyelet toward the pointed needle end l5. The handle 9 has an inclined bore '-|6 extending from the rear end of the handle approximately to the middle of the handle. It will be noted from Figure 4 that the bore l6 has its open end I60, placed on the same side of the handle that corresponds with the back of the needle shank. In other words, a longitudinal plane extending along the groov M of the needle shank will also extend through the end Ilia of the bore I6.

From the foregoing description of the various parts of the device, the operation thereof may be readily understood.

In using the spacer guide and needle to form a plurality of tufts and to secure these tufts to the foundation piece, the bundle D of usually from eighteen to twenty-four strands of any desired length are passed through the spacer guide eye or ring. The length of the bundle can be determined by what colors will be needed for the particular part of the design receiving the tufts. Referring now to Figure 5, it will be noted that a bundle of yarn strands D already have been secured to a foundation piece A by tuft-securing loops. Before describing how a tuft is actually secured to the foundation by a tuft-securing loop, it is best to state that the operator in forming the first tuft takes the spacer guide C and places 'it over one of the guide lines 3 so thatthe prongs 5 and 6 register with the line at one extreme end thereof. The guide is forced toward the fabric for causing the prongs to pierce it and form openings Ila and I'll). After the two openings Have been formed, the spacer guide is lifted and advanced along the line 3 so that the prong 5 will register with the opening l'lb. Care is taken that the longitudinal movement of the spacer guide will not move the bundle D with respect to the foundation piece.

The guide is now pressed into the fabric for the second time, causing the prong 5 to enter the opening 11b and the prong 6 to make opening llc. This will leave the opening "a to the left of the toe 1. A tuft-securing loop F is formed at the opening Ila, the detailed steps of which will be presently described in connection with securing another tuft to the fabric. In like man'- ner, tuft-securing loops F and F? are formed at the opening 11b and He, respectively.

I will now describe in detail how a tuft-securing loop is formed at opening Md. The needle is threaded by taking one end of the tieing yarn Fand passing it through the bore -I 6 and the eyelet I2 from the bottom side, leaving about six inches extending beyond the eyelet. The needle is now used for securing the portion of the bundle of yarn extending past the opening lld to the fabric. Grasp the needle handle in the-right hand, point l6 extending down. Force the point I5 through thehole lld to the depth only of the curved portion, (see first step in Figur 3) then with a half twist, bring the point back through the underside of the cloth and force the needle through the cloth at I9 as shown in the second step in Figure 4. The shank I0 is forced full length through the two openings lld and i9, see Figures 1 and 2.

Draw the needle back slightly until a loop 20 forms on the top side of the needle. With the will permit the free end 2| ofthe tieing yarn F to be grasped by the thumb and finger of the right hand and inserted through the loop 20, the loop being kept in open position by the fingers of the left hand. The needle is now pulled back to force the shank from the fabric as shown in Figure 2. The needle is released and the operator grasps the yarn portion 22 disposed between the needle and the opening I'Id with one hand and grasps the end 2| that extends throughthe loop 20 with the other hand. The portion 22 and the end 2| are now pulled until th loop 20 tightens the strand end 2! over the top of the bundle of yarn strands D. If desired the hand may hold the strand portion F against the handle E for pulling the portion 22 tight.

After the loop 20 has been pulled tight about the end 2|, the portion 22 may be cut from the remaining portion of the tieing strand F that extends through the eye of the needle. The portion 22 may now be twisted around the end 21' as shown by the dot-dash lines in Figure 2, to form the start of a square knot and this knot portion is pulled tight against the bundle D. The same portion 22 and the end 2| are tied together to form the complete square knot, after which the loose ends may be cut with a scissors.

The same operation of tieing the bundle of yarn strands to the fabric is carried on at the next opening He in the fabric A. The tieing strand F is advanced through the eyelet [2 so that the portion extending beyond the eyelet will be about six inches. The grooves l3 and H are provided for receiving a good portion of the tiein strand as the needle isforced through the fabric A and this is clearly shown in Figure 3.

After a second tieing of the bundle D to the fabric A is accomplished, a sharp scissors is used for cutting the strands of yarn midway between the two places of tieing, as at 23. This cutting forms the ends of a tuft G. The spacer guide is advanced each time a tieing takes place and this will position the points of tieing equidistant from each other. The inverted U-shaped toe portion 'I-causes a slight curve to the bundle of strands between adjacent points of tieing.

A continuous operation is possible with the needle and spacer guide because the tieing yarn feeds through the bore in the needle handle and does not interfere with the hand gripping the handle and the yarn is fed as needed through the needle eye. Also the spacer is slipped over the fabric and along the bundle of yarn when it is advanced to its new position. The cutting of the bundle to form tufts is done after each tieing operation. The method can be used in applying strands or tufts of yarn or similar material to cloth, duck, canvas, etc., which is suitably stamped or drawn with design for the making of rugs, bedspreads, pillow tops, runners, etc.

It is possible to lay a continuous row of partially formed tufts by tieing the bundle D at equal spaces to the foundation piece. The cutting can be done later, thereby saving a considerable moved to a new position. The curved needle end makes the pairs of openings Nd and IS the same distance apart. Even stitching of the tufts to the fabric results. The hole 16 in the handle allows sufficient tieing yarn to extend along the handle to grip the yarn for pulling if desired. A double thread is formed over the bundle.

If it is desired to have the tufts of a longer length, it is possible to remove the spacer guide from the position shown in Figure 5, and move it to the right one space. The bundle D now may be cut at a point coinciding with the opening lid after which the guide may be returned to the position shown in Figure 5, care being taken that the bundle is moved to the left with the guide. This will cause longer strand portions to extend to the left of opening Md.

The bundle is tied to the fabric foundation at lid in the same manner as described for the other tieings. Again the spacer is moved to the right two spaces and the bundle cut at the opening fie. This completes one long tuft that is anchored to the foundation at l'ld. To make the second long tuft, the guide is moved to the left one space and the bundle moved with it at which time the second tuft is tied to the fabric at lie. The series of steps are repeated for each long tuft formed. The longer tufts provide a more fluffy rug.

I claim:

1. The herein described method of securing a bundle of several strands of yarn to a foundation piece which comprises forcing a looped portion of a tieing strand through the piece from the upper to the lower side at the desired point adjacent to the bundle and bringing the looped end from the lower to the upper side at a spaced distance from the first point, the two points lying in a line transverse to the length of the bundle,

taking one end of the tieing strand that extends from the upper surface of the first point of insertion and passing it over the bundle and through the loop, pulling on both strand ends in opposite directions to tighten the strand about the bundle for securing it to the piece, and permanently securing the ends together while cutting off any excess portions.

2. The herein described method of securing a pluralityof tufts of a foundation Piece which comprises taking a bundle of several strands and laying the bundle on a foundation piece, forcing a looped portion of a tieing strand through the piece from the upper to the lower side at the desired point adjacent to the bundle and bringing the looped end from'the lower to the upper side at a spaced distance from the first point, the two points lying in a line transverse to the length of the bundle, taking one end of the tieing strand that extends from the upper" surface of the first point of insertion and passing it over the bundle and through the loop, pulling on both strand ends in opposite directions to tighten the.

strand about the bundle for securing it to the piece, and permanently securing the ends together while cutting off any excess portions, repeating the tieing steps for the bundle at a predetermined distance from the first bundle tieing, and severing the bundle midway between the two points of tieing.

3. The herein described method of making scraggy rug with long tufts which comprises taking a number of strands of substantially the same length and forming them into a bundle, placing one end of the bundle on a spacer having a pair of prongs, puncturing a foundation fabric with the prongs, the prongs registering with a contour line on the fabric, mOVlIlg the spacer along the bundle while holding the bundle relative to the fabric and causing the spacer to advance the distance between the prongs, forcing one prong into the opening already made by the other prong and causing a new opening to be made by the other prong, advancing the spacer another similar distance while holding the bundle from moving, tieing the bundle to the fabric at the second. opening, advancing the spacer another similar distance without disturbing the bundle, cutting the bundle at a point corresponding to the third opening in the fabric, returning the spacer to the third position it formerly occupied while moving the bundle therewith, again advancing the spacer two spaces along the bundle while holdingthe latter from moving, tieing the second tuft at the third opening in the fabric, and repeating the process to form as many tufts as desired.

4. The herein described method of securing at least one strand to a foundation Piece which comprises forcing a looped portion of a tieing cord through the piece from the upper to the lower side at the desiredpoint adjacent to the strand and bringing the looped end from the lower to the upper side at a spaced distance from the first point, the two points lying in a line transverse to the length of the strand and on opposite sides thereof, taking one end of the tieing cord that extends from the upper surface of the first point of insertion and passing it over the strand and through the loop, pulling on both cord ends in opposite directions to tighten the cord about the strand for securing it to the piece, and permanently securing the ends of the cord together.

5. The herein described method of securing at least one tuft to a foundation piece which comprises taking at least one strand and laying it on a foundation piece, forcing a looped portion of a tieing cord through the piece from the upper to the lower side at the desired point adjacent to the strand and bringing the looped end from the lower to the upper side at a spaced distance from the first point, the two points lying in a line transverse to the length of the strand and being disposed on opposite sides thereof, taking one end of the tieing cord that extends from the upper surface of the first point of insertion and passing it over the strand and through the loop, pulling on both cord ends in opposite directions to tighten the cord about the strand for securing it to the piece, permanently securing the cord ends together, and severing the strand at spaced distances from the point of tieing.

IRVING FALLEK.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS I Date 

